Safety At Manufacturing Units

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A powerful presentation on safety to bring awareness to ensure safe working environment.

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Safety At Manufacturing Units

  1. 1. SAFETY Slide 1 of 18
  2. 2. Slide 2 of 18 <ul><li>Accident </li></ul><ul><li>Accident Elimination </li></ul><ul><li>Elements of a good Accident Report </li></ul><ul><li>Sharing of Best practices </li></ul>TOPICS
  3. 3. Slide 3 of 18 Accident Gets commonly defined as a “Mishap involving a Person” ACCIDENT <ul><li>Accident should be defined as a “Mishap” involving </li></ul><ul><ul><ul><ul><ul><li>Man </li></ul></ul></ul></ul></ul><ul><ul><ul><ul><ul><li>Machine, </li></ul></ul></ul></ul></ul><ul><ul><ul><ul><ul><li>Product, </li></ul></ul></ul></ul></ul><ul><ul><ul><ul><ul><li>Company Property </li></ul></ul></ul></ul></ul><ul><ul><ul><ul><ul><li>Environment </li></ul></ul></ul></ul></ul>
  4. 4. Slide 4 of 18 <ul><ul><li>1 Anticipate the Accident </li></ul></ul>ACCIDENT ELIMINATION <ul><ul><li>2 Eliminate the Root cause </li></ul></ul><ul><ul><li>3 Isolate the Root cause </li></ul></ul><ul><ul><li>4 Provide Poka Yoke </li></ul></ul><ul><ul><li>5 Provide PPE </li></ul></ul><ul><ul><li>6 Provide Visual / Audible Warning </li></ul></ul><ul><ul><li>9 Horizontal Deployment of CAPA </li></ul></ul><ul><ul><li>7 Mark the Accident Prone spot </li></ul></ul><ul><ul><li>8 Provide Awareness & Training </li></ul></ul><ul><ul><li>10 Involvement of the Masses </li></ul></ul>10 Steps
  5. 5. Slide 5 of 18 <ul><ul><li>1 Anticipate the Accident </li></ul></ul>ACCIDENT ELIMINATION <ul><ul><li>2 Eliminate the Root cause </li></ul></ul><ul><ul><li>3 Isolate the Root cause </li></ul></ul><ul><ul><li>4 Provide Poka Yoke </li></ul></ul><ul><ul><li>5 Provide PPE </li></ul></ul><ul><ul><li>6 Provide A/V Warning </li></ul></ul><ul><ul><li>9 Horizontal Deployment of CAPA </li></ul></ul><ul><ul><li>7 Mark the Accident Prone spot </li></ul></ul><ul><ul><li>8 Provide Awareness & Training </li></ul></ul><ul><ul><li>10 Involvement of the Masses </li></ul></ul>Machine User Safety Manuals MSDS of Raw Material Safety Standards – Govt / Industry Common Knowledge / History Plain Common Sense
  6. 6. Slide 6 of 18 <ul><ul><li>1 Anticipate the Accident </li></ul></ul>ACCIDENT ELIMINATION <ul><ul><li>2 Eliminate the Root cause </li></ul></ul><ul><ul><li>3 Isolate the Root cause </li></ul></ul><ul><ul><li>4 Provide Poka Yoke </li></ul></ul><ul><ul><li>5 Provide PPE </li></ul></ul><ul><ul><li>6 Provide A/V Warning </li></ul></ul><ul><ul><li>9 Horizontal Deployment of CAPA </li></ul></ul><ul><ul><li>7 Mark the Accident Prone spot </li></ul></ul><ul><ul><li>8 Provide Awareness & Training </li></ul></ul><ul><ul><li>10 Involvement of the Masses </li></ul></ul>Meth. Chloride is a harmful chemical Can Meth.Chloride be replaced by Hot Water? Operator risks heat injury while heat sealing 5mm pleat Can the adhesive be changed to non-curing type? Boxes upon boxes of Large ORs piled on shopfloor Can ORs be made online on JIT basis?
  7. 7. Slide 7 of 18 <ul><ul><li>1 Anticipate the Accident </li></ul></ul>ACCIDENT ELIMINATION <ul><ul><li>2 Eliminate the Root cause </li></ul></ul><ul><ul><li>3 Isolate the Root cause </li></ul></ul><ul><ul><li>4 Provide Poka Yoke </li></ul></ul><ul><ul><li>5 Provide PPE </li></ul></ul><ul><ul><li>6 Provide A/V Warning </li></ul></ul><ul><ul><li>9 Horizontal Deployment of CAPA </li></ul></ul><ul><ul><li>7 Mark the Accident Prone spot </li></ul></ul><ul><ul><li>8 Provide Awareness & Training </li></ul></ul><ul><ul><li>10 Involvement of the Masses </li></ul></ul><ul><li>Provision of </li></ul><ul><li>Railing </li></ul><ul><li>Guard </li></ul><ul><li>Make the RC inaccessible by </li></ul><ul><li>Shifting beyond easy reach </li></ul><ul><li>Digitally Secured Doors </li></ul>
  8. 8. Slide 9 of 18 <ul><ul><li>1 Anticipate the Accident </li></ul></ul>ACCIDENT ELIMINATION <ul><ul><li>2 Eliminate the Root cause </li></ul></ul><ul><ul><li>3 Isolate the Root cause </li></ul></ul><ul><ul><li>4 Provide Poka Yoke </li></ul></ul><ul><ul><li>5 Provide PPE </li></ul></ul><ul><ul><li>6 Provide A/V Warning </li></ul></ul><ul><ul><li>9 Horizontal Deployment of CAPA </li></ul></ul><ul><ul><li>7 Mark the Accident Prone spot </li></ul></ul><ul><ul><li>8 Provide Awareness & Training </li></ul></ul><ul><ul><li>10 Involvement of the Masses </li></ul></ul><ul><li>Machine inoperable if RC Isolator removed </li></ul><ul><li>LDR / Laser sensors in Presses </li></ul><ul><li>Sensors linked to Doors of Dangerous areas </li></ul><ul><li>Interlocking to prevent accidental situation </li></ul>
  9. 9. Slide 10 of 18 <ul><ul><li>1 Anticipate the Accident </li></ul></ul>ACCIDENT ELIMINATION <ul><ul><li>2 Eliminate the Root cause </li></ul></ul><ul><ul><li>3 Isolate the Root cause </li></ul></ul><ul><ul><li>4 Provide Poka Yoke </li></ul></ul><ul><ul><li>5 Provide PPE </li></ul></ul><ul><ul><li>6 Provide A/V Warning </li></ul></ul><ul><ul><li>9 Horizontal Deployment of CAPA </li></ul></ul><ul><ul><li>7 Mark the Accident Prone spot </li></ul></ul><ul><ul><li>8 Provide Awareness & Training </li></ul></ul><ul><ul><li>10 Involvement of the Masses </li></ul></ul><ul><li>Next Line of Defense! </li></ul><ul><li>Gloves </li></ul><ul><li>Goggles </li></ul><ul><li>Aprons </li></ul><ul><li>Safety Shoes </li></ul><ul><li>Masks </li></ul><ul><li>Material Handling devices </li></ul>
  10. 10. Slide 11 of 18 <ul><ul><li>1 Anticipate the Accident </li></ul></ul>ACCIDENT ELIMINATION <ul><ul><li>2 Eliminate the Root cause </li></ul></ul><ul><ul><li>3 Isolate the Root cause </li></ul></ul><ul><ul><li>4 Provide Poka Yoke </li></ul></ul><ul><ul><li>5 Provide PPE </li></ul></ul><ul><ul><li>6 Provide A/V Warning </li></ul></ul><ul><ul><li>9 Horizontal Deployment of CAPA </li></ul></ul><ul><ul><li>7 Mark the Accident Prone spot </li></ul></ul><ul><ul><li>8 Provide Awareness & Training </li></ul></ul><ul><ul><li>10 Involvement of the Masses </li></ul></ul>Mfree Line Packing machine There is an audio alarm & a glowing Light when Line restarts Centralised Control Panels For easy monitoring / direct view <ul><li>Airplane Cockpit Meters Principle </li></ul><ul><li>Color coding </li></ul><ul><li>Direction of Needle </li></ul>
  11. 11. Slide 12 of 18 <ul><ul><li>1 Anticipate the Accident </li></ul></ul>ACCIDENT ELIMINATION <ul><ul><li>2 Eliminate the Root cause </li></ul></ul><ul><ul><li>3 Isolate the Root cause </li></ul></ul><ul><ul><li>4 Provide Poka Yoke </li></ul></ul><ul><ul><li>5 Provide PPE </li></ul></ul><ul><ul><li>6 Provide A/V Warning </li></ul></ul><ul><ul><li>9 Horizontal Deployment of CAPA </li></ul></ul><ul><ul><li>7 Mark the Accident Prone spot </li></ul></ul><ul><ul><li>8 Provide Awareness & Training </li></ul></ul><ul><ul><li>10 Involvement of the Masses </li></ul></ul>Caution Boards affixed in 12 Accident Prone areas to alert operators .
  12. 12. Slide 13 of 18 <ul><ul><li>1 Anticipate the Accident </li></ul></ul>ACCIDENT ELIMINATION <ul><ul><li>2 Eliminate the Root cause </li></ul></ul><ul><ul><li>3 Isolate the Root cause </li></ul></ul><ul><ul><li>4 Provide Poka Yoke </li></ul></ul><ul><ul><li>5 Provide PPE </li></ul></ul><ul><ul><li>6 Provide A/V Warning </li></ul></ul><ul><ul><li>9 Horizontal Deployment of CAPA </li></ul></ul><ul><ul><li>7 Mark the Accident Prone spot </li></ul></ul><ul><ul><li>8 Provide Awareness & Training </li></ul></ul><ul><ul><li>10 Involvement of the Masses </li></ul></ul><ul><li>Offline Training Cell </li></ul><ul><li>Accident history of Plant </li></ul><ul><li>Accident History of Cell </li></ul><ul><li>Accident History of Machine / Process </li></ul><ul><li>Evacuation Plans </li></ul><ul><li>Roles & responsibilities </li></ul><ul><li>Practice / Exercise </li></ul><ul><li>Mock drills for </li></ul><ul><li>Mass Food Poisoning </li></ul><ul><li>Earthquake </li></ul><ul><li>Fire </li></ul><ul><li>Electrical shock </li></ul><ul><li>Chemical ingestion </li></ul>
  13. 13. Slide 14 of 18 <ul><ul><li>1 Anticipate the Accident </li></ul></ul>ACCIDENT ELIMINATION <ul><ul><li>2 Eliminate the Root cause </li></ul></ul><ul><ul><li>3 Isolate the Root cause </li></ul></ul><ul><ul><li>4 Provide Poka Yoke </li></ul></ul><ul><ul><li>5 Provide PPE </li></ul></ul><ul><ul><li>6 Provide A/V Warning </li></ul></ul><ul><ul><li>9 Horizontal Deployment of CAPA </li></ul></ul><ul><ul><li>7 Mark the Accident Prone spot </li></ul></ul><ul><ul><li>8 Provide Awareness & Training </li></ul></ul><ul><ul><li>10 Involvement of the Masses </li></ul></ul>Standard Accident Report Including a HD column identifying areas To be closed after HD is completed
  14. 14. Slide 15 of 18 <ul><ul><li>1 Anticipate the Accident </li></ul></ul>ACCIDENT ELIMINATION <ul><ul><li>2 Eliminate the Root cause </li></ul></ul><ul><ul><li>3 Isolate the Root cause </li></ul></ul><ul><ul><li>4 Provide Poka Yoke </li></ul></ul><ul><ul><li>5 Provide PPE </li></ul></ul><ul><ul><li>6 Provide A/V Warning </li></ul></ul><ul><ul><li>9 Horizontal Deployment of CAPA </li></ul></ul><ul><ul><li>7 Mark the Accident Prone spot </li></ul></ul><ul><ul><li>8 Provide Awareness & Training </li></ul></ul><ul><ul><li>10 Involvement of the Masses </li></ul></ul><ul><li>Safety Week </li></ul><ul><li>Declamations, </li></ul><ul><li>Skits, </li></ul><ul><li>Poems, </li></ul><ul><li>Slogans </li></ul><ul><li>“ Work Safely…..We are waiting for you” </li></ul>Sharing of Best practices Groupwide <ul><li>Safety Board </li></ul><ul><li>Accident History & CAPA </li></ul><ul><li>Common precautions </li></ul><ul><li>Whom to contact if….. </li></ul><ul><li>Evacuation Procedure </li></ul><ul><li>Shock value of Visuals </li></ul>
  15. 15. THANKS Slide 17 of 18

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